Tiles and apparatus, system and method for fabricating tiles and tile patterns

Abstract

A router template for fabricating a contoured tile from a workpiece is provided. The router template includes a body that defines a cavity in which a nest is formed for retaining a workpiece during a cutting operation. A bearing path is defined within the body that engages a bearing of the router bit to guide the workpiece relative to the router bit. A cutting path is formed within the body to provide clearance within the body for a rotary cutting portion of the router bit. The cutting path and bearing path are aligned with each other and correspond to the desired size and contour of the tile. A method of cutting a contoured tile by following a template is also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. provisional application Ser. No. 60 / 628,426, filed Nov. 16, 2004.BACKGROUND OF THE INVENTION [0002] 1. Field of the Invention [0003] The invention relates to tiles, more particularly to tiles and apparatuses, systems and methods for fabricating tiles and tile patterns. [0004] 2. Background Art [0005] Conventionally tiles are utilized on floors, walls, furniture or the like to provide an ornamental surface. Often, when tiles are utilized on surfaces such as floors or furniture tops, these surfaces experience pedestrian traffic or wear from objects placed thereupon. [0006] Conventional flooring patterns include simplified patterns and complex patterns. The simplified patterns include wooden flooring and tiles of a uniform polygonal shape, such as rectangular tiles. Neither of which require, nor are provided with, limited tolerances. Minimal gaps are permissible in wood flooring because they gene...

AI Technical Summary

Benefits of technology

[0013] According to another aspect of the invention, a template for moving a workpiece on a table top router as the workpiece is cut to form a contoured product is provided. The router has a bit that is assembled coaxially with a bearing. The template is utilized to cut tiles of a desired shape. The template comprises a body defining a cavity and a nest for retaining the workpiece within the cavity. Means are provided for guiding movement of the template as the workpiece retained in the cavity is moved into engagement with the router bit of the table top router to form the contoured product to the desired shape.

[0014] According to another aspect of the invention, a method of cutting a contoured tile by following a template with a table top router having a cutting

Problems solved by technology

Often, when tiles are utilized on surfaces such as floors or furniture tops, these surfaces experience pedestrian traffic or wear from objects placed thereupon.

If undesired, such gaps are typically filled with a mixture of sawdust and adhesive that is stained to match the associated flooring.

Conventional semi-complicated tile patterns are typically limited to basic geometric shapes, such as lines, circle arcs and the like, and are limited in tolerances as well.

Ceramic or stone tiles are conventionally spaced to receive grouting or tile adhesive therebetween and therefore the lack of precision is unnoticed.

In complex wooden tile patterns, such as tiling, flooring, inlays, borders, parquetry and marquetry, tolerances are lacking thereby generating visually noticeable gaps between adjacent tiles.

These conventional complex wooden tile patterns are costly and labor intensive and any gaps exacerbate these difficulties by requiring filling in the gaps.

Another difficulty presented in wood tiling is that wooden tiles have a tendency to change shape and size due to humidity, drying, application of finishing materials, or the like.

Such methods are typically unavailable to general public consumers.

These methods are also ineffective for some tile materials.

Waterjet cutting can not hold a good tolerance in most applications, (e.g., plus or minus 0.015 inches for most materials).

Additionally, wood tends to absorb water thereby swelling and resulting in an inaccurately cut tile.

Wood has a poor refractive index, thereby resulting in an imprecisely cut tile.

Conventional jigs for woodworking are typically limited in scope, functionality, application, quality and tolerance thereby limiting these characteristics of the resultant workpiece.

Additionally, conventional woodworking jigs are limited in range of variations and styles.

Due to the complexity of tessellations, they are generally only found in artwork, engravings, prints, posters or the like.

Difficulties in reducing tessellated patterns into interlocking tiles is apparent in the prior art.

The prior art has further evolved by providing concrete molds for generating tessellated paver stones that are generally interlocking; however, gaps are provided between adjacent stones as well.

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